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US6627017B2 - Self-adhesive laminate for sealing window frames and method of sealing window frames - Google Patents

Self-adhesive laminate for sealing window frames and method of sealing window frames Download PDF

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Publication number
US6627017B2
US6627017B2 US10/269,591 US26959102A US6627017B2 US 6627017 B2 US6627017 B2 US 6627017B2 US 26959102 A US26959102 A US 26959102A US 6627017 B2 US6627017 B2 US 6627017B2
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United States
Prior art keywords
layer
adhesive
adhesive layer
polyester
laminate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US10/269,591
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US20030039789A1 (en
Inventor
Robert S. Simpson
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Garland Industries Inc
Original Assignee
MFM Building Products Corp
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Publication date
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Priority to US10/269,591 priority Critical patent/US6627017B2/en
Publication of US20030039789A1 publication Critical patent/US20030039789A1/en
Application granted granted Critical
Publication of US6627017B2 publication Critical patent/US6627017B2/en
Assigned to MFM BUILDING PRODUCTS CORP. reassignment MFM BUILDING PRODUCTS CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIMPSON, ROBERT S.
Assigned to 525 ORANGE STREET, INC. reassignment 525 ORANGE STREET, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MFM BUILDING PRODUCTS CORPORATION
Assigned to MFM BUILDING PRODUCTS CORPORATION reassignment MFM BUILDING PRODUCTS CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: 525 ORANGE STREET, INC.
Assigned to GARLAND INDUSTRIES, INC. reassignment GARLAND INDUSTRIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MFM BUILDING PRODUCTS CORPORATION
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
    • B32B15/04Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/66Sealings
    • E04B1/68Sealings of joints, e.g. expansion joints
    • E04B1/6809Reverse side strips
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00Metals, their alloys or their compounds
    • B32B2311/24Aluminium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/006Transparent parts other than made from inorganic glass, e.g. polycarbonate glazings
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • E06B2001/628Separate flexible joint covering strips; Flashings
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/14Layer or component removable to expose adhesive
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/14Layer or component removable to expose adhesive
    • Y10T428/1438Metal containing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/14Layer or component removable to expose adhesive
    • Y10T428/1438Metal containing
    • Y10T428/1443Aluminum
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/14Layer or component removable to expose adhesive
    • Y10T428/1452Polymer derived only from ethylenically unsaturated monomer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372Particulate matter
    • Y10T428/24413Metal or metal compound
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495Thickness [relative or absolute]
    • Y10T428/24959Thickness [relative or absolute] of adhesive layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495Thickness [relative or absolute]
    • Y10T428/24967Absolute thicknesses specified
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31815Of bituminous or tarry residue

Definitions

  • This invention relates generally to a self-adhesive laminate and a method for using this laminate for sealing window frames.
  • prefabricated windows are supplied with a metal flange along their perimeter. This flange is nailed to the building sub-siding. The finish siding is then applied over the flange. The flange is not tightly sealed to the sub-siding and wind-driven rain can cause water leaks around the flange. These leaks can be prevented if a layer of tape is applied to seal the joint between the flange and sub-siding.
  • polyethylene film is easily stretched. If the tape is overstretched, it will tend to contract over time and pull away from the underlying flange. This too creates a deterioration in the seal.
  • the polyethylene absorbs oils present in many adhesive compounds. This causes the polyethylene to swell and wrinkle, also causing a breakdown in the seal formed.
  • roofing uses require a greater degree of strength, due to the nature of their function and the long exposure to the elements of nature.
  • the roofing membranes currently used are also significantly thicker and less flexible than the self-adhesive laminate disclosed herein. Use of such roofing membranes for sealing window frames would be economically impractical due to significantly increased material cost in making the laminate and the increased labor in applying the laminate, due to its stiffness relative to the present invention. Examples of such laminates are shown in the U.S. patents to Tajima et al., U.S. Pat. Nos.
  • the present invention solves these and other problems present in the prior art by providing a number of features.
  • the present invention uses a sheet of transparent or translucent material with a low degree of elasticity, the latter feature tending to prevent overstretching.
  • the present invention incorporates a reflective layer to prevent the overheating of the laminate.
  • the present invention places the reflective layer between the translucent or transparent sheet of material and the adhesive to prevent oils from migrating from the adhesive and into the sheet of material. In these ways, the present invention is a significant improvement over the prior art.
  • the present invention relates to a self-adhesive laminate for sealing window frames.
  • the laminate includes a polyester layer, an aluminum layer, an adhesive layer, and preferably a removable paper or plastic layer overlying the adhesive layer.
  • the removable layer is referred to herein as a release layer.
  • the aluminum layer has a first side and an opposing second side.
  • the polyester layer is adhered to the first side of the aluminum layer.
  • the adhesive layer is applied to the second side of the aluminum layer.
  • the release layer overlies the adhesive remote from the aluminum layer.
  • the aluminum layer preferably is between about 10 nm and about 100 nm thick.
  • the polyester layer is preferably transparent or translucent and is between about 0.00045 in. and about 0.002 in. thick.
  • the adhesive layer is preferably pressure-sensitive and is between about 0.015 in. and about 0.060 in. thick.
  • the aluminum and polyester are preferably adhered to one another by depositing the aluminum layer on the polyester layer by vapor deposition.
  • the adhesive is preferably based on rubberized asphalt, butyl rubber, or polyisobutylene.
  • the adhesive is most preferably a rubberized asphalt comprising asphalt, thermoplastic elastomers, process oil, and tackifying resins.
  • FIG. 1 is a sectional view of the self-adhesive laminate according to the present invention.
  • FIG. 2 is a partial sectional view of the self-adhesive laminate in use to seal the joint between a window frame and an adjacent wall.
  • the present invention relates to a self-adhesive laminate 1 used in sealing window frames.
  • the laminate includes three primary elements, a polyester layer 10 , a metallic aluminum layer 12 , and an adhesive layer 14 .
  • the polyester layer 10 and the aluminum layer 12 are preferably integrally formed.
  • the aluminum layer 12 may be deposited on the polyester layer 10 in any manner which is commonly used in the industry, such as via vapor deposition techniques, for example, or other equivalent means.
  • the polyester film is preferably between about 0.00045 in. and about 0.02 in. thick.
  • the aluminum layer is preferably between about 10 nm and about 100 nm thick.
  • the adhesive layer 14 is adhered to the side of the aluminum layer 12 remote from the polyester layer 10 .
  • the adhesive layer 14 is preferably a rubberized asphalt, most preferably made from asphalt, thermoplastic elastomers, process oil and tackifying resins.
  • the adhesive layer 14 is an adhesive based on butyl rubber or polyisobutylene.
  • the adhesive layer 14 preferably has a thickness between about 0.015 in. and about 0.060 in.
  • a release layer 16 is applied to be adjacent the adhesive layer 14 , remote from the aluminum layer 11 .
  • the aluminum layer 12 be placed between the adhesive layer 14 and the polyester layer 10 .
  • the adhesives used in the adhesive layer 14 tend to include oils, such as the process oil mentioned above.
  • the adhesive layer is placed adjacent a polyethylene sheet. Over time, the oils from the adhesive layer contact the polyethylene sheet and, to a certain extent, leach into or are absorbed by the polyethylene sheet. This leaching causes the polyethylene sheet to swell, wrinkle, degrade and fail over time.
  • the aluminum layer 12 between the polyester layer 10 and the adhesive layer 14 acts as a barrier to the oils in the adhesive layer relative to the polyester sheet 10 . The oils do not degrade the aluminum layer 12 and are not transferred through the aluminum layer to the polyester sheet 10 . Therefore, the polyester sheet 10 is not subject to degradation by these oils to the extent present in the prior art. Further, since the polyester layer 10 is relatively strong, it provides protection to the aluminum layer from exposure to the elements and contact with outside agencies.
  • polyester sheet 10 rather than the polyethylene sheet used in the prior art is also highly preferred.
  • Polyester and polyethylene have very different elasticities. When a polyethylene sheet is used, a person applying such an adhesive tape can relatively easily overstretch the tape. Over time, the tape is likely to contract and separate from the wall surface to which the tape is applied.
  • a polyester sheet as is used in the present invention, has a lower degree of elasticity than the polyethylene sheet used in the prior art tapes. This characteristic reduces this type of human error during use because the risk of overstretching is significantly minimized. In testing, the vastly different elasticities become apparent.
  • the polyester layer be translucent or transparent.
  • Such a polyester layer permits ambient light, specifically sunlight, to penetrate the polyester layer and reflect from the aluminum layer. This reflection of light permits the adhesive layer to remain at a temperature which is close to ambient temperature.
  • the installation of window frames and the application of an adhesive tape to seal the joint with the sub-siding may occur several days or weeks before the installation of the final siding material. Therefore, the tape is exposed to sunlight, rain, wind, and the like. It is important that the sealing function of the tape remain effective, particularly during this openly exposed time period prior to installation of the overlying final siding layers.
  • the prior art laminates using a dark colored polyethylene film can be heated on a typical summer day to a temperature as much as 25 degrees F. higher than ambient temperature. Even using a light colored polyethylene film in such laminates as those used in the prior art, the temperature of the adhesive layer can rise to as much as 10-15 degrees F. higher than ambient temperature. When the temperature of the adhesive increases to this degree, the tape can become hot to the touch, making it difficult to handle and more difficult to apply properly.
  • the adhesive layer loses some of its tackiness and may not form a proper seal or the originally formed seal may degrade after application to cause failure of the sealing function. It is therefore highly preferred to use a translucent or transparent polyester sheet with the aluminum layer in accordance with the present invention to reflect light and heat to prevent overheating of the laminate tape and the detrimental consequences thereof.
  • the adhesive laminate is used as a moisture seal around windows in new construction and replacement installations. It may also be used as an underlayment to seal joints and other openings beneath a variety of exterior surfaces including brick, stucco, wood, and vinyl or metal siding.
  • the laminate may be applied directly to most vertical or horizontal surfaces, including surfaces made of wood, composition wood panels, metal, vinyl, and masonry.
  • the surface to which the laminate is to be applied is preferably clean, dry, and free from oil, grease, and debris. Dirty, dusty or weathered surfaces should be primed with a water-based, polymer-based, or solvent-based primer to obtain a clean, smooth surface, prior to application of the laminate.
  • the laminate may be attached with mechanical fasteners, such as nails, screws, staples, or other types of fasteners, if the surface cannot be made reasonably smooth.
  • the laminate is preferably applied at temperatures above 50 degrees F.
  • FIG. 2 shows a wall 20 in which a window frame 22 has been placed.
  • a flange 24 extends from the window frame 22 adjacent the wall 20 .
  • the laminate 1 is applied in a sealingly disposed overlying relationship across the flange 24 and wall 20 .
  • the laminate 1 engages the flange 24 and the wall 20 and the seam between the flange 24 and the wall 20 as is described below.
  • the laminate is applied along the window flange or other joint to join the flange to the surrounding surfaces, such as the outer wall. It is installed by removing the release layer 16 and pressing the adhesive layer 14 onto the surface.
  • the laminate may be cut to fit an appropriate length using scissors or a utility knife.
  • the sheet of laminate is preferably unrolled gradually, without stretching.
  • the release layer is removed and the adhesive pressed against the surface. Any air pockets should be eliminated.
  • a hand-held roller may be used along seams to ensure smooth, uninterrupted contact between the surface and the laminate.
  • the laminate is being applied around a window, it is important that it be applied to cause water not to flow into overlapping areas.
  • strips of the laminate are applied along the bottom of the window. Then, strips are applied along the sides of the window, overlapping the portion applied to the bottom. Finally, strips are applied at the top of the window, overlapping the strips applied to the sides. The strips should be overlapped between about 3 in. and about 6 in.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)
  • Adhesives Or Adhesive Processes (AREA)

Abstract

A self-adhesive laminate for sealing window frames includes an aluminum layer having a first side and a second side, a polyester layer adhered to the first side of the aluminum layer, an adhesive layer adhered to the second side of the aluminum layer, and a release paper overlying the adhesive remote from the aluminum layer. This laminate reduces or eliminates the overheating problems common in prior art tapes.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a division of co-pending application Ser. No. 09/627,635 filed on Jul. 28, 2000 now U.S. Pat. No. 6,479,119.
(Not Applicable)
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
(Not Applicable)
Reference to a “Microfiche Appendix”
(Not Applicable)
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a self-adhesive laminate and a method for using this laminate for sealing window frames.
2. Description of the Related Art
In building construction, prefabricated windows are supplied with a metal flange along their perimeter. This flange is nailed to the building sub-siding. The finish siding is then applied over the flange. The flange is not tightly sealed to the sub-siding and wind-driven rain can cause water leaks around the flange. These leaks can be prevented if a layer of tape is applied to seal the joint between the flange and sub-siding.
Various types of adhesive tapes or laminates have been used to seal these flanges. These laminates generally are dark-colored and comprise a polyethylene film adhered to a bitumen layer. However, the use of such a tape has several disadvantages.
First, due to the dark color of the tape, exposure to sunlight causes it to become heated above ambient temperatures. This can cause difficulty in application of the tape and creates problems with adequate adhesion at higher temperatures, causing the seal formed upon application of the tape to deteriorate. Even if a light-colored polyethylene is used, the tape still absorbs sufficient heat to adversely affect adhesion.
Second, polyethylene film is easily stretched. If the tape is overstretched, it will tend to contract over time and pull away from the underlying flange. This too creates a deterioration in the seal.
Finally, the polyethylene absorbs oils present in many adhesive compounds. This causes the polyethylene to swell and wrinkle, also causing a breakdown in the seal formed.
Some prior art adhesive laminates include a variety of layers. However, these laminates are not feasible for use in the present application. First, these products are designed to be used on roofing. Roofing uses require a greater degree of strength, due to the nature of their function and the long exposure to the elements of nature. The roofing membranes currently used are also significantly thicker and less flexible than the self-adhesive laminate disclosed herein. Use of such roofing membranes for sealing window frames would be economically impractical due to significantly increased material cost in making the laminate and the increased labor in applying the laminate, due to its stiffness relative to the present invention. Examples of such laminates are shown in the U.S. patents to Tajima et al., U.S. Pat. Nos. 3,937,640 and 4,055,453; Yamamoto, U.S. Pat. No. 4,374,687; Clapperton, U.S. Pat. No. 4,386,981; Crepeau, U.S. Pat. No. 4,514,442; Paeglis et al., U.S. Pat. No. 4,589,804; Cooper et al., U.S. Pat. No. 4,670,071; and Simpson et al., U.S. Pat. No. 5,096,759.
The present invention solves these and other problems present in the prior art by providing a number of features. First, the present invention uses a sheet of transparent or translucent material with a low degree of elasticity, the latter feature tending to prevent overstretching. Next, the present invention incorporates a reflective layer to prevent the overheating of the laminate. Finally, the present invention places the reflective layer between the translucent or transparent sheet of material and the adhesive to prevent oils from migrating from the adhesive and into the sheet of material. In these ways, the present invention is a significant improvement over the prior art.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a self-adhesive laminate for sealing window frames. The laminate includes a polyester layer, an aluminum layer, an adhesive layer, and preferably a removable paper or plastic layer overlying the adhesive layer. The removable layer is referred to herein as a release layer.
The aluminum layer has a first side and an opposing second side. The polyester layer is adhered to the first side of the aluminum layer. The adhesive layer is applied to the second side of the aluminum layer. The release layer overlies the adhesive remote from the aluminum layer.
The aluminum layer preferably is between about 10 nm and about 100 nm thick. The polyester layer is preferably transparent or translucent and is between about 0.00045 in. and about 0.002 in. thick. The adhesive layer is preferably pressure-sensitive and is between about 0.015 in. and about 0.060 in. thick. The aluminum and polyester are preferably adhered to one another by depositing the aluminum layer on the polyester layer by vapor deposition.
The adhesive is preferably based on rubberized asphalt, butyl rubber, or polyisobutylene. The adhesive is most preferably a rubberized asphalt comprising asphalt, thermoplastic elastomers, process oil, and tackifying resins.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a sectional view of the self-adhesive laminate according to the present invention; and
FIG. 2 is a partial sectional view of the self-adhesive laminate in use to seal the joint between a window frame and an adjacent wall.
In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word connected or term similar thereto are often used. They are not limited to direct connection, but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art. In addition, many elements are illustrated which are of a type which perform well-known operations. Those skilled in the art will recognize that there are many, and in the future may be additional, alternative elements which are recognized as equivalent because they provide the same operations.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a self-adhesive laminate 1 used in sealing window frames. The laminate includes three primary elements, a polyester layer 10, a metallic aluminum layer 12, and an adhesive layer 14.
The polyester layer 10 and the aluminum layer 12 are preferably integrally formed. The aluminum layer 12 may be deposited on the polyester layer 10 in any manner which is commonly used in the industry, such as via vapor deposition techniques, for example, or other equivalent means. The polyester film is preferably between about 0.00045 in. and about 0.02 in. thick. The aluminum layer is preferably between about 10 nm and about 100 nm thick.
An adhesive layer 14 is adhered to the side of the aluminum layer 12 remote from the polyester layer 10. The adhesive layer 14 is preferably a rubberized asphalt, most preferably made from asphalt, thermoplastic elastomers, process oil and tackifying resins. Alternatively, the adhesive layer 14 is an adhesive based on butyl rubber or polyisobutylene. The adhesive layer 14 preferably has a thickness between about 0.015 in. and about 0.060 in. A release layer 16 is applied to be adjacent the adhesive layer 14, remote from the aluminum layer 11.
It is important that the aluminum layer 12 be placed between the adhesive layer 14 and the polyester layer 10.
The adhesives used in the adhesive layer 14 tend to include oils, such as the process oil mentioned above. In prior art devices, the adhesive layer is placed adjacent a polyethylene sheet. Over time, the oils from the adhesive layer contact the polyethylene sheet and, to a certain extent, leach into or are absorbed by the polyethylene sheet. This leaching causes the polyethylene sheet to swell, wrinkle, degrade and fail over time. In the present invention, the aluminum layer 12 between the polyester layer 10 and the adhesive layer 14 acts as a barrier to the oils in the adhesive layer relative to the polyester sheet 10. The oils do not degrade the aluminum layer 12 and are not transferred through the aluminum layer to the polyester sheet 10. Therefore, the polyester sheet 10 is not subject to degradation by these oils to the extent present in the prior art. Further, since the polyester layer 10 is relatively strong, it provides protection to the aluminum layer from exposure to the elements and contact with outside agencies.
Use of the polyester sheet 10, rather than the polyethylene sheet used in the prior art is also highly preferred. Polyester and polyethylene have very different elasticities. When a polyethylene sheet is used, a person applying such an adhesive tape can relatively easily overstretch the tape. Over time, the tape is likely to contract and separate from the wall surface to which the tape is applied. A polyester sheet, as is used in the present invention, has a lower degree of elasticity than the polyethylene sheet used in the prior art tapes. This characteristic reduces this type of human error during use because the risk of overstretching is significantly minimized. In testing, the vastly different elasticities become apparent. A polyethylene film having a thickness of 0.0015 in. was tested and found to have an elongation of 264% and a breaking strength of 5.5 lbs./in. A polyester film having a thickness of 0.00075 in., i.e., half the thickness of the polyethylene film, when subjected to the same tests, was found to have an elongation of 69% and a breaking strength of 21 lbs./in.
It is also preferred that the polyester layer be translucent or transparent. Such a polyester layer permits ambient light, specifically sunlight, to penetrate the polyester layer and reflect from the aluminum layer. This reflection of light permits the adhesive layer to remain at a temperature which is close to ambient temperature. In the construction of homes and other buildings, the installation of window frames and the application of an adhesive tape to seal the joint with the sub-siding may occur several days or weeks before the installation of the final siding material. Therefore, the tape is exposed to sunlight, rain, wind, and the like. It is important that the sealing function of the tape remain effective, particularly during this openly exposed time period prior to installation of the overlying final siding layers.
Exposure of the prior art adhesive laminates to sunlight causes the temperature of those adhesives to significantly increase and represents a significant problem unsolved by those in the field for many years. The prior art laminates using a dark colored polyethylene film can be heated on a typical summer day to a temperature as much as 25 degrees F. higher than ambient temperature. Even using a light colored polyethylene film in such laminates as those used in the prior art, the temperature of the adhesive layer can rise to as much as 10-15 degrees F. higher than ambient temperature. When the temperature of the adhesive increases to this degree, the tape can become hot to the touch, making it difficult to handle and more difficult to apply properly. In addition, when the temperature of the adhesive is too high, the adhesive layer loses some of its tackiness and may not form a proper seal or the originally formed seal may degrade after application to cause failure of the sealing function. It is therefore highly preferred to use a translucent or transparent polyester sheet with the aluminum layer in accordance with the present invention to reflect light and heat to prevent overheating of the laminate tape and the detrimental consequences thereof.
The adhesive laminate is used as a moisture seal around windows in new construction and replacement installations. It may also be used as an underlayment to seal joints and other openings beneath a variety of exterior surfaces including brick, stucco, wood, and vinyl or metal siding. The laminate may be applied directly to most vertical or horizontal surfaces, including surfaces made of wood, composition wood panels, metal, vinyl, and masonry. For best results, the surface to which the laminate is to be applied is preferably clean, dry, and free from oil, grease, and debris. Dirty, dusty or weathered surfaces should be primed with a water-based, polymer-based, or solvent-based primer to obtain a clean, smooth surface, prior to application of the laminate. The laminate may be attached with mechanical fasteners, such as nails, screws, staples, or other types of fasteners, if the surface cannot be made reasonably smooth. The laminate is preferably applied at temperatures above 50 degrees F.
An example of the use of the laminate 1 is shown in FIG. 2. FIG. 2 shows a wall 20 in which a window frame 22 has been placed. A flange 24 extends from the window frame 22 adjacent the wall 20. The laminate 1 is applied in a sealingly disposed overlying relationship across the flange 24 and wall 20. The laminate 1 engages the flange 24 and the wall 20 and the seam between the flange 24 and the wall 20 as is described below.
The laminate is applied along the window flange or other joint to join the flange to the surrounding surfaces, such as the outer wall. It is installed by removing the release layer 16 and pressing the adhesive layer 14 onto the surface. The laminate may be cut to fit an appropriate length using scissors or a utility knife.
The sheet of laminate is preferably unrolled gradually, without stretching. The release layer is removed and the adhesive pressed against the surface. Any air pockets should be eliminated. A hand-held roller may be used along seams to ensure smooth, uninterrupted contact between the surface and the laminate.
If the laminate is being applied around a window, it is important that it be applied to cause water not to flow into overlapping areas. Preferably, strips of the laminate are applied along the bottom of the window. Then, strips are applied along the sides of the window, overlapping the portion applied to the bottom. Finally, strips are applied at the top of the window, overlapping the strips applied to the sides. The strips should be overlapped between about 3 in. and about 6 in.
While certain preferred embodiments of the present invention have been disclosed in detail, it is to be understood that various modifications may be adopted without departing from the spirit of the invention or scope of the following claims.

Claims (13)

What is claimed is:
1. A method for sealing window frames provided with a surrounding flange installed in a wall section of a building comprising, in combination, the steps of:
a) providing a laminate strip comprising a layer of aluminum adhered between an adhesive layer and a polyester layer:
b) applying said laminate in overlying and sealing relationship to a portion of the surrounding flange of the window frame and the surface of the adjacent wall section to seal a seam formed by an edge of the frame and adjacent surface of the wall section with said adhesive layer engaging the flange of the window frame and the adjacent wall section and the polyester layer facing outwardly relative to the adhesive layer.
2. The method according to claim 1 wherein said layer of aluminum has a thickness of between about 10 nm and 100 nm.
3. The method according to claim 1, wherein the polyester layer has a thickness between about 0.00045 in. and about 0.0002 in.
4. The method according to claim 1, wherein the polyester layer is transparent.
5. The method according to claim 1, wherein the polyester layer is translucent.
6. The method according to claim 1, wherein the adhesive layer is pressure-sensitive.
7. The method according to claim 1, wherein the adhesive layer has a thickness between about 0.015 in. and about 0.060 in.
8. The method according to claim 1, wherein adhesive layer comprises rubberized asphalt.
9. The method according to claim 1, herein the rubberized asphalt comprises asphalt, thermoplastic elastomers, process oil, and tackifying resins.
10. The method according to claim 1, wherein the adhesive layer comprises a butyl rubber-based adhesive.
11. The method according to claim 1, wherein the adhesive layer comprises a polyisobutylene-based adhesive.
12. The method according to claim 1, wherein the layer of aluminum is applied to the polyester layer by vapor deposition.
13. The method according to claim 1, further comprising a release layer overlying the adhesive remote from the aluminum layer.
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